Step 5: Belts and cape

Step 6: Accessories

There are two pouches that measure about 5"x 6" x2" thick that are secured to the ammo belt. I made them by gluing fabric around foam blocks. There sh...

This Halloween I wanted to make a really cool costume but I had a very tight budget. So I looked around the garage and I found a couple of sheets of cardboard, some blue foam, plastic sheet, some brown vinyl, lots of various colors of spray paint, etc. I also had a flight suit from a previous costume.

The first thought that came into my mind was Boba Fett- the notorious bounty hunter from Star Wars. In costuming circles, Fett is considered to be one of the most difficult, time consuming and expensive costumes there is for a Star Wars character and a lot of people will say that a decent looking Fett costume can't be made inexpensively. I'd like to thank each and every member of The Dented Helmet- the best Boba Fett costume resource for all their help, advice, templates and reference material! Without these guys this never would have happened.

Here's how I made my Fett costume on a limited budget and in a short period of time.

Step 1: Materials

You'll need:two to three large sheets of cardboard- the sheets I used are called newspaper board (about 1/16" thick and measure 30" x 40") It's available at craft stores and picture framing shops.hot glue gun with lots of gluewhite glueblue foam board (a section of 2x4 scrap lumber will also work)sheet plastic- I used 1/8" thick Sintra for the armor (available from plastics suppliers and sign shops) and regular styrene ( for sale signs) for the jetpack missilesome velcrocotton/canvas dropcloth- available at Home Depot for $10cotton clothsline- 40ft. or so, about 1/4" diameterbelt buckle (any kind will do but the plastic click lock kind work pretty well)flight suit- grey is preferred but I had a tan one on handlightweight spackling pastesmall can of Minwax Polycrylic sealeraluminum soda cans (four of them)dark green fabric dyedark tinted plastic for the helemt visorspray paint- one can of the following: white, red, olive green, burgundy, black, blue, silver, yellow

There are also several templates that you'll need. This have been graciously provided by Alan (Wizard of Flight) of The Dented Helmet board. All of these templates can be also be scaled down so that a children's costume can be constructed.

hey your costume is great fantastic job im in the middle of making my own thanks to WOF and those impressive templates. I would like to know what kind of cardboard you used . and how much spacling is needed for armour pieces

The type of cardboard I used is called newspaper board- it's primarily sold at craft stores and shops that do picture framing. You really don't need much spackling- it's just there to smooth out seams and rough spots.

I don't know the overall dimensions- I gave my costume to a friend several years ago so I have no way of measuring it. I do know that the patterns are dimensioned from the movie jetpack and the actor that played Fett is 6 feet tall so you should be just fine.

Whats up! Im almost done my Boba Fett costume for Halloween! I honestly couldn't have done it without your tutorial Honus. I just need to do the Boots, Gloves, Blaster, and attach the Cod Piece and back belt to the suit. I finished the jet pack today, and it turned out amazing. I'd just like to thank you for taking your time to put up this tutorial, It really helped me out alot!

About This Instructable

Bio:I'm a former bicycle industry designer turned professional jeweler. I like working with my hands and am happiest when I'm in the shop building my creations. If you need help with your project just let...read more »